Method of machining surfaces of rotor disc and grinding machine therefor

ABSTRACT

A method of manufacturing turned surfaces of a rotor disc of a gas turbine engine, including rotating the rotor disc about its central axis, rotating an abrasive grinding wheel having an outer grinding surface with a hardness greater than that of a material of the rotor disc, contacting the rotating wheel with at least one annular surface of the rotating disc, and sliding the rotating wheel along a curved cross-sectional profile of the at least one annular surface of the rotating disc.

TECHNICAL FIELD

The application relates generally to rotor discs for gas turbine enginesand, more particularly, to the machining of such discs.

BACKGROUND OF THE ART

Rotors of gas turbine engines such as turbine rotors, compressorimpeller rotors, rotors with separate or with integral blades, etc.,typically have a rotor disc (whether integral with or separatelymanufactured from the blades) with turned surfaces. Such turnedsurfaces, and particularly those having a curved cross-sectionalprofiles, are typically machined by a turning method where the rotatingrotor disc is put into contact with a stationary or translating pointtool grinding the surface to the desired profile.

Improvements in fuel efficiency lead to gas turbine engines being run athigher temperatures. As such, harder materials are used to form theparts of the gas turbine engines. Such materials having high temperaturestrength and hardness are more difficult to machine. The resistance ofthese materials can be such as to produce, for example, excessive wearof the point tools, breakage of the point tool tips, chipping of thepoint tools, reduced machining speeds, and/or damaged workpiecesurfaces.

SUMMARY

In one aspect, there is provided a method of manufacturing turnedsurfaces of a rotor disc of a gas turbine engine, the method comprising:rotating the rotor disc about a central axis thereof; rotating anabrasive grinding wheel, the abrasive grinding wheel having an outergrinding surface with a hardness greater than that of a material of therotor disc; contacting the rotating wheel with at least one annularsurface of the rotating disc; and sliding the rotating wheel along acurved cross-sectional profile of the at least one annular surface ofthe rotating disc.

In another aspect, there is provided a method of finishing all turnedsurfaces having a curved cross-sectional profile in a rotor disc of agas turbine engine, the method comprising: retaining the rotor disc in aretaining mechanism; rotating the rotor disc about a central axisthereof with the retaining mechanism; and while rotating the rotor disc,sliding at least one rotating grinding wheel having a hardness greaterthan that of a material of the rotor disc along the cross-sectionalprofile of each of the turned surfaces having a curved cross-sectionalprofile without disengaging the rotating rotor disc from the retainingmechanism

In a further aspect, there is provided a grinding machine for finishingturned surfaces of a rotor disc for a gas turbine engine, the machinecomprising: a retaining mechanism configured for retaining the rotordisc, the retaining mechanism being rotatable about a rotational axiscorresponding to a central axis of the rotor disc; a spindle engaged toa grinding wheel, the spindle being rotatable about a rotational axiscorresponding to a central axis of the grinding wheel, the grindingwheel having an outer super abrasive surface; a translating mechanismengaged to at least one of the retaining mechanism and the spindle, thetranslating mechanism providing a relative translational motion betweenthe retaining mechanism and the spindle along three perpendicular axes;and a pivoting mechanism engaged to one of the retaining mechanism andthe spindle, the pivoting mechanism providing a pivoting motion of therotational axis of one of the retaining mechanism and the spindle arounda pivot axis perpendicular thereto.

DESCRIPTION OF THE DRAWINGS

Reference is now made to the accompanying figures in which:

FIG. 1 is a schematic cross-sectional view of a gas turbine engine;

FIG. 2 a is a schematic front view of a grinding wheel;

FIG. 2 b is a schematic front cross-sectional view of the grinding wheelof FIG. 2 a, taken along line B-B thereof;

FIG. 3 is a partial schematic cross-sectional view of a rotor disc whichcan be used in a gas turbine engine such as shown in FIG. 1 havinginternal and external axial surfaces being machined using a grindingwheel such as shown in FIGS. 2 a-2 b;

FIG. 4 is a partial schematic cross-sectional view of the rotor disc ofFIG. 3 having a curved annular surface of a face profile being machinedwith the grinding wheel;

FIG. 5 is a partial schematic cross-sectional view of the rotor disc ofFIG. 3 having a curved surface of a pocket profile being machined withthe grinding wheel;

FIG. 6 is a partial schematic cross-sectional view of the rotor disc ofFIG. 3 having a curved annular surface of another face profile beingmachined with the grinding wheel;

FIG. 7 is a partial schematic cross-sectional view of the rotor disc ofFIG. 3 having a curved surface of another pocket profile being machinedwith the grinding wheel;

FIG. 8 is a partial schematic cross-sectional view of the rotor disc ofFIG. 3 having a curved surface of an annular groove being machined witha smaller grinding wheel;

FIG. 9 is a partial schematic cross-sectional view of the rotor disc ofFIG. 3 having a curved surface of an annular lip being machined with thesmaller grinding wheel;

FIG. 10 is a schematic front view of a grinding machine which can beused to machine the turned surfaces of a rotor disc such as shown inFIG. 3; and

FIG. 11 is a schematic top view of another grinding machine which can beused to machine the turned surfaces of a rotor disc such as shown inFIG. 3.

DETAILED DESCRIPTION

FIG. 1 illustrates a gas turbine engine 10 of a type preferably providedfor use in subsonic flight, generally comprising in serial flowcommunication a fan 12 through which ambient air is propelled, acompressor section 14 for pressurizing the air, a combustor 16 in whichthe compressed air is mixed with fuel and ignited for generating anannular stream of hot combustion gases, and a turbine section 18 forextracting energy from the combustion gases.

The gas turbine engine 10 includes a plurality of rotors, such as forexample a high pressure compressor impeller rotor 20 in the compressorsection 14 and a high pressure turbine rotor 22 in the turbine section18. Although the gas turbine 10 is shown here as a turbofan, the enginecan be any other type of gas turbine engine, for example turboshaftengines and turboprop engines.

Referring to FIG. 3, a rotor disc 24 is partially shown. In theembodiment shown, the disc 24 includes blade slots 26 each sized toreceive the root of a blade therein (not shown). In another embodiment,the rotor disc 24 is part of an integrally bladed rotor, i.e. where therotor and the blades are machined as one piece.

In a particular embodiment, the rotor disc 24 is made of a materialhaving a hardness of at least 50 HRC (Rockwell scale C). In a particularembodiment, the rotor disc 24 is made of a material selected from anickel super alloy, a nickel-based powder metal, a metal matrixcomposite, and a metal matrix ceramic. Particular examples include, butare not limited to, Direct Aged Inconel 718, IN100 powder nickel alloyand ME16 powder nickel alloy.

The rotor disc 24 includes a plurality of turned surfaces, i.e. annularsurfaces which have a constant cross-sectional profile around thecircumference of the disc 24 and as such can be machined by a turningmethod. The rotor disc 24 includes a hub 28 defining an annular internalsurface 30 which extends axially, i.e. parallel to the central axis C₁of the rotor disc. The rotor disc 24 also includes an annular externalsurface 32 in which the blade slots 26 are defined, which also extendsaxially.

The turned surfaces also include a plurality of surfaces which have acurved cross-sectional profile, viewed as a curve in across-section suchas that of FIG. 3. A curved turned surface 34 is defined by the faceprofile of one side of the rotor disc 24, defining a first annularrecess 34 a in that side, extending substantially from the hub 28 to theblade slots 26. Other curved turned surfaces 36, 38 are defined byannular pockets 36 a, 38 a on each side of the hub 28. Another curvedturned surface 40 is defined by the face profile of the opposite side ofthe rotor disc 24, defining an annular recess 40 a in that sideextending adjacent the hub 28. An annular groove 42 a is definedradially outwardly from the second annular recess 40 a, and is separatedtherefrom by a lip 44 a. The annular groove 42 a and lip 44 a alsodefine annular surfaces 42, 44 having curved cross-sectional profiles.In addition to or in replacement to some or to all of the abovedescribes surfaces, the rotor may include other curved turned surfacesresulting from other face profiling, pocketing, grooving, etc.

As shown in FIG. 3, the axial annular internal and external surfaces 30,32 may be machined by a wheel turn grinding method, through slidingengagement with an abrasive wheel 46. Referring to FIGS. 4-9, instead ofbeing conventionally turned with a point tool, at least one of thecurved turned surfaces 34, 36, 38, 40, 42, 44, on which prior machiningsteps may have been performed, is finished by turning using a grindingwheel 46, 146. More than one grinding wheel 46, 146 can be used, withthe wheel(s) being designed to insure accurate machining of thecorresponding part features and at the same time avoid collision andinterference with the remainder of the disc.

Each grinding wheel 46, 146 has a hardness which is greater than that ofthe material of the rotor disc 24. In a particular embodiment, thegrinding wheel(s) 46, 146 are super abrasive wheels including an outersuper abrasive surface such as a plated, brazed or vitrified layer withcubic Boron Nitride (cBN) grits, or a plated or brazed layer withdiamond grits. The core material of the grinding wheel(s) 46, 146 mayvary, and include for example aluminium for lower rotational speeds andsteel, titanium or carbon fiber for higher rotational speeds.

Turn grinding wheels 46, 146 are positioned and continuously fedaccurately along the workpiece surface. Referring to FIG. 10, anexemplary 5-axis turn grinding machine 50 is shown, similar to a millingmachine. The disc 24 is installed on a retaining mechanism 52 whichretains the disc 24 in position and rotates it about a rotational axisR₁ corresponding to the central axis C₁ of the disc 24. The machine 50also includes a spindle 54 to which is interchangeably engaged eachgrinding wheel 46, 146, and which is rotatable about a rotational axisR₂ corresponding to the central axis C₂ of the grinding wheel 46, 146. Atranslating mechanism includes a first portion 56 engaged to theretaining mechanism 52 to slide it along a Z-axis, and a second portion58 engaged to the spindle to slide it along X and Y axes; thetranslating mechanism thus provides a relative translational motionbetween the retaining mechanism 52 and the spindle 54 along the threeperpendicular axes X, Y and Z. A pivoting mechanism 60 is engaged to theretaining mechanism 52 and pivots its rotational axis R₁ around a pivotaxis P perpendicular thereto.

Referring to FIG. 11, another exemplary 5-axis turn grinding machine 150is shown, similar to a turning machine or lathe. The disc 24 isinstalled on a retaining mechanism 152 which retains the disc 24 inposition and rotates it about a rotational axis R₁ corresponding to thecentral axis C₁ of the disc 24. The machine 150 also includes a spindle154 to which is interchangeably engaged each grinding wheel 46, 146, andwhich is rotatable about a rotational axis R₂ corresponding to thecentral axis C₂ of the grinding wheel 46, 146. A translating mechanismis engaged to the spindle 154 to slide it along X and Y axes, includinga linear X drive 156 received on a double linear Y drive 158. Thetranslating mechanism includes a portion engaged to either the spindle154 or the retaining mechanism 152 to slide it along the z-axis. Apivoting mechanism 160 is engaged to the spindle 154 and provides apivoting motion of its rotational axis R₂ around a pivot axis Pperpendicular thereto.

Other configurations for the grinding machine 50, 150 are also possible.

Referring to FIGS. 2 a-2 b, each wheel is defined with a particularwheel diameter D, wheel tip radius R, wheel taper angle A, wheel taperlength L and wheel web thickness T. These wheel parameters aredetermined based on the required geometrical feature(s) of the surfaceto be machined and the accessibility limits to that surface. Thegeometrical feature(s) and accessibility limits also determine how thewheel 46, 146 is moved and the relative orientation between the wheel46, 146 and the rotor disc 24. Wheel extensions (not shown) can be usedto increase the wheel reach and avoid collision. The wheel taper angle Aand length L can be adjusted to avoid interference with adjacentportions of the disc 24. The wheel tip radius R can be selected to matchthe required final fillet radii on the finished disc 24.

In use, curved turned surfaces of the rotor disc 24 are thus machined orfinished by engaging the rotor disc 24 in a retaining mechanism 52, 152of a grinding machine 50, 150 such as for example one of the machines ofFIGS. 10-11. The rotor disc 24 is rotated about its central axis C₁ bythe retaining mechanism 52, 152. The abrasive grinding wheel 46, 146 ofthe grinding machine 50, 150 is rotated. The rotating wheel 46, 146 isput in contact with each curved turned surface 34, 36, 38, 40, 42, 44being machined, and slides along the curved cross-sectional profile ofthe surface. The relative orientation between the wheel 46, 146 and thedisc 24 may be varied as the wheel slides along the cross-sectionalprofile and/or between the machining of two different surfaces, asrequired.

For example, FIGS. 4 and 6 show the use of a grinding wheel 46 tomachine the curved turned surface 34, 40 defined by the face profile ofthe opposed sides of the rotor disc 24. The relative motion between therotating wheel 46 and rotor disc 24 is controlled such that the wheel 46follows the corresponding face profile of the disc 24. The wheel tiplocation and relative orientation between the wheel and rotor disc arecontrolled to avoid interference or collision with the remainder of thedisc 24. The wheel geometry is also selected to allow access to thecomplete profile of the curved surfaces 34, 40, and may also be definedto correspond to geometrical features such as fillet radii and depths inthe face profile.

FIGS. 5 and 7 shows the use of the grinding wheel 46 to machine thecurved turned surfaces 36, 38 defined by the pockets 36 a, 38 a on theopposed sides of the disc hub 28. The wheel geometry may be adapted toefficiently reach the tough pocket areas which might represent achallenge for conventional turning methods using a point tool.

In the embodiment shown, the same grinding wheel 46 is used to machinethe curved turned surfaces 34, 36, 38, 40 of FIGS. 4-7; in anotherembodiment. different wheels are used to machine at least some of thecurved turned surfaces.

FIG. 8 shows the use of a smaller grinding wheel 146 to machine thecurved turned surface 42 of the annular groove 42 a in one face of therotor disc. FIG. 9 shows the use of the grinding wheel 146 to machinethe inner annular surface 44 of the lip 44 a bordering the annulargroove 42 a. Before contacting the rotating wheel 146 with the innersurfaces 42, 44 of the groove 42 a and lip 44 e. at least part of therotating wheel 146 is inserted and positioned in the annular groove 42a, and if required behind the annular lip 44 a, without contacting therotor disc 24; the wheel 146 is thus sized according to the size of thegroove 42 a to be machined. In the embodiment shown, both surfaces 42,44 are machined using the same grinding wheel 146; in anotherembodiment, different grinding wheels may be used.

In a particular embodiment, all of the turned surfaces 30, 32, 34, 36,38, 40, 42, 44 of the rotor disc 24, curved and straight, are machinedusing one or more grinding wheels 46, 146 in a single machiningoperation, without disengaging the rotor disc 24 from the retainingmechanism 52, 152 of the grinding machine. In a particular embodiment,the rotor disc 24 continuously rotates during the machining of all theturned surfaces.

During the machining process, the turn grinding wheel 46, 146 andspindle 54, 154 rotate at high speed, for example to provide a wheelsurface speed of up to 50000 surface feet per minute (SFM). The wheelsurface speed depends on the spindle rotational speed and on the wheeldiameter.

The rotor disc 24 may rotate at a lower rotational speed, for example upto 2000 rpm. In a particular embodiment, the rotational speed of therotor disc 24 is adjusted during the grinding to maintain a same contactsurface speed between the rotor disc 24 and the grinding wheel 46, 146as the rotating wheel 46, 146 slides along the annular surface beingmachined and/or as the wheel 46, 146 contacts different annularsurfaces. Different portions of the rotor disc 24 having differentdiameters rotate at different surface speeds if the rotational speedremains constant, and adjusting the rotational speed as a function ofthe diameter of the annular surface being machined allows for thesurface speed to remain constant or within a given range.

In the case where the rotor disc 24 includes blade slots 26, the turnedsurfaces may be machined with the turn grinding wheel(s) 46, 146 eitherbefore or after the slots 26 are machined in the rotor disc 24. In aparticular embodiment, machining the turned surfaces prior to the bladeslots 26 provides datum surface(s) used as reference for the machiningof the blade slots 26.

In a particular embodiment, the use of grinding wheels 46, 146 tomachine the turned surfaces of the rotor disc 24 provides for a higherquality of the machined surfaces (as opposed to turning with a pointtool), which may improve the life of the rotor disc 24. The turngrinding process with grinding wheels is able to machine chips at ahigher rate and more efficiently than conventional turning with a pointtool, especially for hard materials such as super alloys.

The use of turn grinding wheels 46, 146 when compared to conventionalsingle point tools generally allows for the use of harder cutting edges,an increased number of cutting edges used (along the circumference ofthe grinding wheel), and faster speeds of the machining operation. Sincewith turn grinding wheels each pass of the abrasive grit removes only avery small chip load, the machining forces and generated heat aregenerally limited, which may results in a better surface quality of themachined surface, which in turn may allow for a longer life of the rotordisc.

The above description is meant to be exemplary only, and one skilled inthe art will recognize that changes may be made to the embodimentsdescribed without departing from the scope of the invention disclosed.For example, the machining operations described may be used with rotordiscs having different geometrical features than that shown. Still othermodifications which fall within the scope of the present invention willbe apparent to those skilled in the art, in light of a review of thisdisclosure, and such modifications are intended to fall within theappended claims.

1. A method of manufacturing turned surfaces of a rotor disc of a gasturbine engine, the method comprising: rotating the rotor disc about acentral axis thereof; rotating an abrasive grinding wheel, the abrasivegrinding wheel having an outer grinding surface with a hardness greaterthan that of a material of the rotor disc; contacting the rotating wheelwith at least one annular surface of the rotating disc; and sliding therotating wheel along a curved cross-sectional profile of the at leastone annular surface of the rotating disc.
 2. The method as defined inclaim 1, wherein sliding the rotating wheel includes varying a relativeorientation between the wheel and the disc.
 3. The method as defined inclaim 1, wherein the at least one annular surface includes first andsecond annular surfaces of the disc, the method further comprisingvarying a relative orientation between the wheel and the disc whilerotating the disc between sliding the rotating wheel along the curvedcross-sectional profile of the first annular surface and contacting therotating wheel with the second annular surface.
 4. The method as definedin claim 1, wherein rotating the abrasive grinding wheel includesrotating the grinding outer surface having a layer of cubic boronnitride or diamond grits.
 5. The method as defined in claim 1, whereinthe at least one annular surface includes all turned surfaces of therotor disc having curved cross-sectional profiles.
 6. The method asdefined in claim 1, further comprising adjusting a rotational speed ofthe rotor disc to maintain a same given contact surface speed betweenthe rotor and the wheel as the rotating wheel slides along the at leastone annular surface.
 7. The method as defined in claim 1, wherein thematerial of the rotor disc has a hardness of at least 50 HRC.
 8. Themethod as defined in claim 1, wherein before contacting the rotatingwheel with the at least one annular surface of the rotating disc, therotating wheel is at least partly inserted in an annular groove of therotor disc without contacting the rotor disc, the at least one annularsurface including an inner surface of the annular groove.
 9. The methodas defined in claim 1, wherein at least partly inserting the rotatingwheel in the annular groove includes manoeuvring the rotating wheelbehind an annular lip bordering the groove, the at least one annularsurface including a surface of the annular lip located within thegroove.
 10. The rotor disc machined according to the method as definedin claim
 1. 11. A turbine disc, compressor impeller or integrally bladedrotor including the rotor disc as defined in claim
 10. 12. A method offinishing all turned surfaces having a curved cross-sectional profile ina rotor disc of a gas turbine engine, the method comprising: retainingthe rotor disc in a retaining mechanism; rotating the rotor disc about acentral axis thereof with the retaining mechanism; and while rotatingthe rotor disc, sliding at least one rotating grinding wheel having ahardness greater than that of a material of the rotor disc along thecross-sectional profile of each of the turned surfaces having a curvedcross-sectional profile without disengaging the rotating rotor disc fromthe retaining mechanism.
 13. The method as defined in claim 12, whereinsliding the at least one rotating wheel includes varying a relativeorientation between the at least one rotating wheel and the rotatingdisc as the at least one rotating wheel slides along the cross-sectionalprofile.
 14. The method as defined in claim 12, wherein sliding the atleast one rotating wheel includes varying a relative orientation betweenthe at least one rotating wheel and the rotating disc between slidingthe at least one rotating wheel along the cross-sectional profile of afirst one of the turned surfaces and along the cross-sectional profileof a second one of the turned surfaces.
 15. The method as defined inclaim 12, further comprising adjusting a rotational speed of the rotordisc to maintain a same given contact surface speed between the rotordisc and the at least one grinding wheel as the wheel slides along eachof the turned surfaces.
 16. The method as defined in claim 12, whereinsliding the at least one grinding wheel includes contacting a rotatingouter surface having a layer of cubic boron nitride or diamond gritswith each of the turned surfaces.
 17. The method as defined in claim 12,wherein before sliding the at least one rotating grinding wheel alongthe cross-sectional profile of one of the turned surfaces, the at leastone rotating grinding wheel is at least partly inserted in an annulargroove of the rotating rotor disc without contacting the rotor disc, theone of the turned surfaces being an inner surface of the annular groove.18. A grinding machine for finishing turned surfaces of a rotor disc fora gas turbine engine, the machine comprising: a retaining mechanismconfigured for retaining the rotor disc, the retaining mechanism beingrotatable about a rotational axis corresponding to a central axis of therotor disc; a spindle engaged to a grinding wheel, the spindle beingrotatable about a rotational axis corresponding to a central axis of thegrinding wheel, the grinding wheel having an outer super abrasivesurface; a translating mechanism engaged to at least one of theretaining mechanism and the spindle, the translating mechanism providinga relative translational motion between the retaining mechanism and thespindle along three perpendicular axes; and a pivoting mechanism engagedto one of the retaining mechanism and the spindle, the pivotingmechanism providing a pivoting motion of the rotational axis of one ofthe retaining mechanism and the spindle around a pivot axisperpendicular thereto.
 19. The machine as defined in claim 18, whereinthe spindle is detachably engaged to the grinding wheel and the machinefurther includes at least one additional grinding wheel interchangeablewith the grinding wheel and having a different geometry therefrom. 20.The machine as defined in claim 18, wherein the outer grinding surfaceof the grinding wheel includes carbon boron nitride or diamond grits.